Soft absorbent sheets, structuring fabrics for making soft absorbent sheets, and methods of making soft absorbent sheets

ABSTRACT

Soft absorbent sheets, structuring fabrics for producing soft absorbent sheets, and methods of making soft absorbent sheets. The soft absorbent sheets have a plurality of domed regions or projected regions extending from a surface of the sheets, and connecting regions form a network between domed regions. The domed and projected regions include indented bars that extend across the domed and projected regions in a substantially cross machine direction of the absorbent sheets. The absorbent sheets can be formed by structuring fabrics that have long warp yarn knuckles.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.15/912,848, filed Mar. 6, 2018, now U.S. Pat. No. 9,963,831, issued Jun.25, 2019. U.S. patent application Ser. No. 15/912,848 is a divisional ofU.S. patent application Ser. No. 15/175,949, filed Jun. 7, 2016, nowU.S. Pat. No. 9,963,831, issued May 8, 2018, which 2018. U.S. patentapplication Ser. No. 15/175,949 claims the benefit of priority of U.S.Provisional Patent Application No. 62/172,659, filed Jun. 8, 2015. Theforegoing applications are incorporated by reference herein in theirentireties.

FIELD OF THE INVENTION

Our invention relates to paper products such as absorbent sheets. Ourinvention also relates to methods of making paper products such asabsorbent sheets, as well as to structuring fabrics for making paperproducts such as absorbent sheets.

RELATED ART

The use of fabrics is well known in the papermaking industry forimparting structure to paper products. More specifically, it is wellknown that a shape can be provided to paper products by pressing amalleable web of cellulosic fibers against a fabric and thensubsequently drying the web. The resulting paper products are therebyformed with a molded shape corresponding to the surface of the fabric.The resulting paper products also thereby have characteristics resultingfrom the molded shape, such as a particular caliper and absorbency. Assuch, a myriad of structuring fabrics has been developed for use inpapermaking processes to provide products with different shapes andcharacteristics. And, fabrics can be woven into a near limitless numberof patterns for potential use in papermaking processes.

One important characteristic of many absorbent paper products issoftness—consumers want, for example, soft paper towels. Many techniquesfor increasing the softness of paper products, however, have the effectof reducing other desirable properties of the paper products. Forexample, calendering basesheets as part of a process for producing papertowels can increase the softness of the resulting paper towels, butcalendering also has the effect of reducing the caliper and absorbencyof the paper towels. On the other hand, many techniques for improvingother important properties of paper products have the effect of reducingthe softness of the paper products. For example, wet and dry strengthresins can improve the underlying strength of paper products, but wetand dry strength resins also reduce the perceived softness of theproducts.

For these reasons, it is desirable to make softer paper products, suchas absorbent sheets. And, it is desirable to be able to make such softerabsorbent sheets through manipulation of a structuring fabric used inthe process of making the absorbent sheets.

SUMMARY OF THE INVENTION

According to one aspect, our invention provides an absorbent sheet ofcellulosic fibers that has a first side and a second side. The absorbentsheet includes a plurality of domed regions projecting from the firstside of the sheet, with each of the domed regions including a pluralityof indented bars extending across a respective domed region in asubstantially cross machine direction (CD) of the absorbent sheet.Connecting regions form a network interconnecting the domed regions ofthe absorbent sheet.

According to another aspect, our invention provides an absorbent sheetof cellulosic fibers that has a first side and a second side. Theabsorbent sheet includes a plurality of domed regions projecting fromthe first side of the sheet, wherein each domed region is positionedadjacent to another domed region such that a staggered line of domedregions extends substantially along the MD of the absorbent sheet. Theabsorbent sheet also includes connecting regions forming a networkinterconnecting the domed regions of the absorbent sheet, wherein eachconnecting region is substantially continuous with two other connectingregions such that substantially continuous lines of connecting regionsextend in a stepped manner along the MD of the absorbent sheet.

According to yet another aspect, our invention provides an absorbentsheet of cellulosic fibers that has a first side and a second side. Theabsorbent sheet includes a plurality of domed regions projecting fromthe first side of the sheet, with each of the domed regions extending adistance of at least about 2.5 mm in the MD of the absorbent sheet. Eachof the plurality of domed regions includes an indented bar extendingacross a respective domed region in a substantially CD of the absorbentsheet, with the indented bar extending a depth of at least about 45microns below the adjacent portions of the domed region. Further,connecting regions form a network interconnecting the domed regions ofthe absorbent sheet.

According to still another aspect, our invention provides a method ofmaking a paper product. The method includes forming an aqueouscellulosic web on a structuring fabric in a papermaking machine, withthe structuring fabric including knuckles formed on warp yarns of thestructuring fabric, and with the knuckles having a length in the MD ofthe absorbent sheet and a width in the CD of the absorbent sheet. Aplanar volumetric density index of the structuring fabric multiplied bythe ratio of the length of the knuckles and the width of the knuckleswidth is about 43 to about 50. The method further includes steps ofdewatering the cellulosic web on the structuring fabric, andsubsequently drying the cellulosic web to form the absorbent sheet.

According to a further aspect, our invention provides an absorbentcellulosic sheet that has a first side and a second side, with theabsorbent sheet including projected regions extending from the firstside of the sheet. The projected regions extend substantially in the MDof the absorbent sheet, with each of the projected regions including aplurality of indented bars extending across the projected regions in asubstantially CD of the absorbent sheet, and with the projected regionsbeing substantially parallel to each other. Connecting regions areformed between the projected regions, with the connecting regionsextending substantially in the MD.

According to yet another aspect, our invention provides a method ofmaking a fabric-creped absorbent cellulosic sheet. The method includescompactively dewatering a papermaking furnish to form a web having aconsistency of about 30 percent to about 60 percent. The web is crepedunder pressure in a creping nip between a transfer surface and astructuring fabric. The structuring fabric includes knuckles formed onwarp yarns of the structuring fabric, with the knuckles having a lengthin the machine direction (MD) of the absorbent sheet and a width in thecross machine direction (CD) of the absorbent sheet. A planar volumetricdensity index of the structuring fabric multiplied by the ratio of thelength of the knuckles and the width of the knuckles width is at leastabout 43. The method also includes drying the web to form the absorbentcellulosic sheet.

According to one further aspect, our invention provides a method ofmaking a fabric-creped absorbent cellulosic sheet. The method includescompactively dewatering a papermaking furnish to form a web. The web iscreped under pressure in a nip between a transfer surface and astructuring fabric. The structuring fabric has machine direction (MD)yarns that form (i) knuckles extending in substantially MD lines alongthe structuring fabric, and (ii) substantially continuous lines ofpockets extending in substantially MD lines along the structuring fabricbetween the lines of knuckles. The structuring fabric also has crossmachine direction (CD) yarns that are completely located below a planedefined by the knuckles of the MD yarns. The method also includes dryingthe web to form the absorbent cellulosic sheet.

According to yet another aspect, our invention provides a method ofmaking a fabric-creped absorbent cellulosic sheet. The method includescompactively dewatering a papermaking furnish to form a web having aconsistency of about 30 percent to about 60 percent. The method furtherincludes creping the web under pressure in a creping nip between atransfer surface and a structuring fabric and drying the web to form theabsorbent cellulosic sheet. The absorbent sheet has SAT capacities of atleast about 9.5 g/g and at least about 500 g/m2. Further, a crepingratio is defined by the speed of the transfer surface relative to thespeed of the structuring fabric, and the creping ratio is less thanabout 25%.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a papermaking machine configurationthat can be used in conjunction with our invention.

FIG. 2 is a top view of a structuring fabric for making paper productsaccording to an embodiment our invention.

FIGS. 3A-3F indicate characteristics of structuring fabrics according toembodiments of our invention and characteristics of comparisonstructuring fabrics.

FIGS. 4A-4E are photographs of absorbent sheets according to embodimentsof our invention.

FIG. 5 is an annotated version of the photograph shown in FIG. 4E.

FIGS. 6A and 6B are cross-sectional views of a portion of an absorbentsheet according to an embodiment of our invention and a portion of acomparison absorbent sheet, respectively.

FIGS. 7A and 7B show laser scans for determining the profile of portionsof absorbent sheets according to embodiments of our invention.

FIG. 8 indicates characteristics of structuring fabrics according toembodiments of our invention and a comparison structuring fabric.

FIG. 9 shows the characteristics of basesheets that were made using thestructuring fabrics characterized in FIG. 8.

FIGS. 10A-10D indicate characteristics of still further structuringfabrics according to embodiments of our invention.

FIGS. 11A-11E are photographs of absorbent sheets according toembodiments of our invention.

FIGS. 12A-12E are photographs of further absorbent sheets according toembodiments of our invention.

FIG. 13 indicates characteristics of structuring fabrics according toembodiments of our invention and a comparison structuring fabric.

FIG. 14 shows a measurement of a profile along one of the warp yarns ofa structuring fabric according to an embodiment of our invention.

FIG. 15 is a chart showing fabric crepe percentage versus caliper forbasesheets made with a fabric according to an embodiment of ourinvention and a comparative fabric.

FIG. 16 is a chart showing fabric crepe percentage versus SAT capacityfor basesheets made with a fabric according to an embodiment of ourinvention and a comparative fabric.

FIG. 17 is a chart showing fabric crepe percentage versus caliper forbasesheets made with different furnishes and a fabric according to anembodiment of our invention.

FIG. 18 is a chart showing fabric crepe percentage versus SAT capacityfor basesheets made with different furnishes and a fabric according toan embodiment of our invention.

FIG. 19 is a chart showing fabric crepe percentage versus void volumefor basesheets made with a fabric according to an embodiment of ourinvention and a comparative fabric.

FIGS. 20(a) and 20(b) are soft x-ray images of an absorbent sheetaccording to an embodiment of our invention.

FIGS. 21(a) and 21(b) are soft x-ray images of an absorbent sheetaccording to another embodiment of our invention.

FIGS. 22(a)-22(e) are photographs of absorbent sheets according tofurther embodiments of our invention.

FIGS. 23(a) and 23(b) are photographs of an absorbent sheet according toan embodiment of our invention and a comparison absorbent sheet.

FIGS. 24(a) and 24(b) are photographs of cross sections of the absorbentsheets shown in FIGS. 23(a) and 23(b).

DETAILED DESCRIPTION OF THE INVENTION

Our invention relates to paper products such as absorbent sheets andmethods of making paper products such as absorbent sheets. Absorbentpaper products according to our invention have outstanding combinationsof properties that are superior to other absorbent paper products thatare known in the art. In some specific embodiments, the absorbent paperproducts according to our invention have combinations of propertiesparticularly well suited for absorbent hand towels, facial tissues, ortoilet paper.

The term “paper product,” as used herein, encompasses any productincorporating papermaking fibers having cellulose as a majorconstituent. This would include, for example, products marketed as papertowels, toilet paper, facial tissue, etc. Papermaking fibers includevirgin pulps or recycled (secondary) cellulosic fibers, or fiber mixescomprising cellulosic fibers. Wood fibers include, for example, thoseobtained from deciduous and coniferous trees, including softwood fibers,such as northern and southern softwood kraft fibers, and hardwoodfibers, such as eucalyptus, maple, birch, aspen, or the like. Examplesof fibers suitable for making the products of our invention includenon-wood fibers, such as cotton fibers or cotton derivatives, abaca,kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse,milkweed floss fibers, and pineapple leaf fibers.

“Furnishes” and like terminology refers to aqueous compositionsincluding papermaking fibers, and, optionally, wet strength resins,debonders, and the like, for making paper products. A variety offurnishes can be used in embodiments of our invention, and specificfurnishes are disclosed in the examples discussed below. In someembodiments, furnishes are used according to the specificationsdescribed in U.S. Pat. No. 8,080,130 (the disclosure of which isincorporated by reference in its entirety). The furnishes in this patentinclude, among other things, cellulosic long fibers having a coarsenessof at least about 15.5 mg/100 mm. Examples of furnishes are alsospecified in the examples discussed below.

As used herein, the initial fiber and liquid mixture that is dried to afinished product in a papermaking process will be referred to as a “web”and/or a “nascent web.” The dried, single-ply product from a papermakingprocess will be referred to as a “basesheet.” Further, the product of apapermaking process may be referred to as an “absorbent sheet.” In thisregard, an absorbent sheet may be the same as a single basesheet.Alternatively, an absorbent sheet may include a plurality of basesheets,as in a multi-ply structure. Further, an absorbent sheet may haveundergone additional processing after being dried in the initialbasesheet forming process in order to form a final paper product from aconverted basesheet. An “absorbent sheet” includes commercial productsmarketed as, for example, hand towels.

When describing our invention herein, the terms “machine direction” (MD)and “cross machine direction” (CD) will be used in accordance with theirwell-understood meaning in the art. That is, the MD of a fabric or otherstructure refers to the direction that the structure moves on apapermaking machine in a papermaking process, while CD refers to adirection crossing the MD of the structure. Similarly, when referencingpaper products, the MD of the paper product refers to the direction onthe product that the product moved on the papermaking machine in thepapermaking process, and the CD of the product refers to the directioncrossing the MD of the product.

FIG. 1 shows an example of a papermaking machine 200 that can be used tomake paper products according to our invention. A detailed descriptionof the configuration and operation of papermaking machine 200 can befound in U.S. Pat. No. 7,494,563 (“the '563 patent”), the disclosure ofwhich is incorporated by reference in its entirety. Notably, the '563patent describes a papermaking process that does not use through airdrying (TAD).

The following is a brief summary of a process for forming an absorbentsheet using papermaking machine 200.

The papermaking machine 200 is a three-fabric loop machine that includesa press section 100 in which a creping operation is conducted. Upstreamof the press section 100 is a forming section 202. The forming section202 includes headbox 204 that deposits an aqueous furnish on a formingwire 206 supported by rolls 208 and 210, thereby forming an initialaqueous cellulosic web 116. The forming section 202 also includes aforming roll 212 that supports a papermaking felt 102 such that web 116is also formed directly on the felt 102. The felt run 214 extends abouta suction turning roll 104 and then to a shoe press section 216 whereinthe web 116 is deposited on a backing roll 108. The web 116 iswet-pressed concurrently with the transfer to the backing roll 108,which carries the web 116 to a creping nip 120. In other embodiments,however, instead of being transferred on the backing roll 108, the web116 by be transferred from the felt run 214 onto an endless belt in adewatering nip, with the endless belt then carrying the web 116 to thecreping nip 120. An example of such a configuration can be seen in U.S.Pat. No. 8,871,060, which is incorporated by reference herein in itsentirety.

The web 116 is transferred onto the structuring fabric 112 in thecreping nip 120, and then vacuum drawn by vacuum molding box 114. Afterthis creping operation, the web 116 is deposited on Yankee dryer 218 inanother press nip 217 using a creping adhesive. The web 116 is dried onYankee dryer 218, which is a heated cylinder, and the web 116 is alsodried by high jet velocity impingement air in the Yankee hood around theYankee dryer 218. As the Yankee dryer 218 rotates, the web 116 is peeledfrom the dryer 218 at position 220. The web 116 may then be subsequentlywound on a take-up reel (not shown). The reel may be operated slowerthan the Yankee dryer 218 at steady-state in order to impart a furthercrepe to the web. Optionally, a creping doctor blade 222 may be used toconventionally dry-crepe the web 116 as it is removed from the Yankeedryer 218.

In a creping nip 120, the web 116 is transferred onto the top side ofthe structuring fabric 112. The creping nip 120 is defined between thebacking roll 108 and the structuring fabric 112, with the structuringfabric 112 being pressed against the backing roll 108 by the crepingroll 110. Because the web still has a high moisture content when it istransferred to the structuring fabric 112, the web is deformable suchthat portions of the web can be drawn into pockets formed between theyarns that make up the structuring fabric 112. (The pockets ofstructuring fabrics will be described in detail below.) In particularpapermaking processes, the structuring fabric 112 moves more slowly thanthe papermaking felt 102. Thus, the web 116 is creped as it istransferred onto the structuring fabric 112.

An applied suction from vacuum molding box 114 may also aid in drawingthe web 116 into pockets in the surface of the structuring fabric 112,as will be described below. When traveling along the structuring fabric112, the web 116 reaches a highly consistent state with most of themoisture having been removed. The web 116 is thereby more or lesspermanently imparted with a shape by the structuring fabric 112, withthe shape including domed regions where the web 116 is drawn into thepockets of the structuring fabric 112.

Basesheets made with papermaking machine 200 may also be subjected tofurther processing, as is known in the art, in order to convert thebasesheets into specific products. For example, the basesheets may beembossed, and two basesheets can be combined into multi-ply products.The specifics of such converting processes are well known in the art.

Using the process described in the aforementioned '563 patent, the web116 is dewatered to the point that it has a higher consistency whentransferred onto the top side of the structuring fabric 112 compared toan analogous operation in other papermaking processes, such as a TADprocess. That is, the web 116 is compactively dewatered so as to havefrom about 30 percent to about 60 percent consistency (i.e., solidscontent) before entering the creping nip 120. In the creping nip 120,the web is subjected to a load of about 30 PLI to about 200 PLI.Further, there is a speed differential between the backing roll 108 andthe structuring fabric 112. This speed differential is referred to asthe fabric creping percentage, and may be calculated as:Fabric Crepe %=S1/S2−1where S1 is the speed of the backing roll 108 and S2 is the speed of thestructuring fabric 112. In particular embodiments, the fabric crepepercentage can be anywhere from about 3% to about 100%. This combinationof web consistency, velocity delta occurring at the creping nip, thepressure employed at the creping nip 120, and the structuring fabric 112and nip 120 geometry act to rearrange the cellulose fibers while the web116 is still pliable enough to undergo structural change. In particular,without intending to be bound by theory, it is believed that the slowerforming surface speed of the structuring fabric 112 causes the web 116to be substantially molded into openings in the structuring fabric 116,with the fibers being realigned in proportion to the creping ratio.

While a specific process has been described in conjunction with thepapermaking machine 200, those skilled in the art will appreciate thatour invention disclosed herein is not limited to the above-describedpapermaking process. For example, as opposed to the non-TAD processdescribed above, our invention could be related to a TAD papermakingprocess. An example of a TAD papermaking process can be seen in U.S.Pat. No. 8,080,130, the disclosure of which is incorporated by referencein its entirety.

FIG. 2 is a drawing showing details of a portion of the web contactingside of the structuring fabric 300 that has a configuration for formingpaper products according to an embodiment of our invention. The fabric300 includes warp yarns 302 that run in the machine direction (MD) whenthe fabric is used in a papermaking process, and weft yarns 304 that runin the cross machine direction (CD). The warp and weft yarns 302 and 304are woven together so as to form the body of the structuring fabric 300.The web-contacting surface of the structuring fabric 300 is formed byknuckles (two of which are outlined in FIG. 2 and labeled as 306 and310), which are formed on the warp yarns 302, but no knuckles are formedon the weft yarns 304. It should be noted, however, that while thestructuring fabric 300 shown in FIG. 2 only has knuckles on the warpyarns 302, our invention is not limited to structuring fabrics that onlyhave warp knuckles, but rather, includes fabrics that have both warp andweft knuckles. Indeed, fabrics with only warp knuckles and fabrics withboth warp and weft knuckles will be described in detail below.

The knuckles 306 and 310 in fabric 300 are in a plane that makes up thesurface that the web 116 contacts during a papermaking operation.Pockets 308 (one of which is shown as the outlined area in FIG. 2) aredefined in the areas between the knuckles 306 and 310. Portions of theweb 116 that do not contact the knuckles 306 and 310 are drawn into thepockets 308 as described above. It is the portions of the web 116 thatare drawn into the pockets 308 that result in domed regions that arefound in the resulting paper products.

Those skilled in the art will appreciate the significant length of warpyarn knuckles 306 and 310 in the MD of structuring fabric 300, and willfurther appreciate that the fabric 300 is configured such that the longwarp yarn knuckles 306 and 310 delineate long pockets in the MD. Inparticular embodiments of our invention, the warp yarn knuckles 306 and310 have a length of about 2 mm to about 6 mm. Most structuring fabricsknown in the art have shorter warp yarn knuckles (if the fabrics haveany warp yarn knuckles at all). As will be described below, the longerwarp yarn knuckles 306 and 310 provide for a larger contact area for theweb 116 during the papermaking process, and, it is believed, might be atleast partially responsible for the increased softness seen in absorbentsheets according to our invention, as compared to absorbent sheets withconventional, shorter warp yarn knuckles.

To quantify the parameters of the structuring fabrics described herein,the fabric characterization techniques described in U.S. PatentApplication Publication Nos. 2014/0133734; 2014/0130996; 2014/0254885,and 2015/0129145 (hereafter referred to as the “fabric characterizationpublications”) can be used. The disclosures of the fabriccharacterization publications are incorporated by reference in theirentirety. Such fabric characterization techniques allow for parametersof a structuring fabric to be easily quantified, including knucklelengths and widths, knuckle densities, pocket areas, pocket densities,pocket depths, and pocket volumes.

FIGS. 3A-3E indicate some of the characteristics of structuring fabricsmade according to embodiments of our invention, which are labeled asFabrics 1-15. FIG. 3F also shows characteristics of conventionalstructuring fabrics, which are labeled as Fabrics 16 and 17. Structuringfabrics of the type shown in FIGS. 3A-3F can be made by a numerousmanufacturers, including Albany International of Rochester, N.H. andVoith GmbH of Heidenheim, Germany. Fabrics 1-15 have long warp yarnknuckle fabrics such that the vast majority of the contact area inFabrics 1-15 comes from the warp yarn knuckles, as opposed to weft yarnknuckles (if the fabrics have any weft yarn knuckles at all). Fabrics 16and 17, which have shorter warp yarn knuckles, are provided forcomparison. All of the characteristics shown in FIGS. 3A-3F weredetermined using the techniques in the aforementioned fabriccharacterization publications, particularly, using the non-rectangular,parallelogram calculation methods that are set forth in the fabriccharacterization publications. Note that the indications of “N/C” inFIGS. 3A-3F mean that the particular characteristics were notdetermined.

The air permeability of a structuring fabric is another characteristicthat can influence the properties of paper products made with thestructuring fabric. The air permeability of a structuring fabric ismeasured according to well-known equipment and tests in the art, such asFrazier® Differential Pressure Air Permeability Measuring Instruments byFrazier Precision Instrument Company of Hagerstown, Md. Generallyspeaking, the long warp knuckle structuring fabrics used to producepaper products according to our invention have a high amount of airpermeability. In a particular embodiment of our invention, the long warpknuckle structuring fabric has an air permeability of about 450 CFM toabout 1000 CFM.

FIGS. 4A-4E are photographs of absorbent sheets made with long warpknuckle structuring fabrics, such as those characterized in FIGS. 3A-3E.More specifically, FIGS. 4A-4E show the air side of the absorbentsheets, that is, the side of the absorbent sheets that contacted thestructuring fabric during the process of forming the absorbent sheets.Thus, the distinct shapes that are imparted to the absorbent sheetsthrough contact with the structuring fabrics, including domed regionsprojecting from the shown side of the absorbent sheet, can be seen inFIGS. 4A-4E. Note that the MD of the absorbent sheets is shownvertically in these figures.

Specific features of the absorbent sheet 1000 are annotated in FIG. 5,which is the photograph shown as FIG. 4E. The absorbent sheet 1000includes a plurality of substantially rectangular-shaped domed regions,some of which are outlined and labeled 1010, 1020, 1030, 1040, 1050,1060, 1070, and 1080 in FIG. 5. As explained above, the domed regions1010, 1020, 1030, 1040, 1050, 1060, 1070, and 1080 correspond to theportions of the web that were drawn into the pockets of the structuringfabric during the process of forming the absorbent sheet 1000.Connecting regions, some of which are labeled 1015, 1025, and 1035 inFIG. 5, form a network interconnecting the domed regions. The connectingregions generally correspond to portions of the web that were formed inthe plane of the knuckles of the structuring fabric during the processof forming the absorbent sheet 1000.

Those skilled in the art will immediately recognize several features ofthe absorbent sheets shown in FIGS. 4A-4E and 5 that are different thanconventional absorbent sheets. For instance, all of the domed regionsinclude a plurality of indented bars formed into the tops of the domedregions, with the indented bars extending across the domed regions inthe CD of the absorbent sheets. Some of these indented bars are outlinedand labeled 1085 in FIG. 5. Notably, almost all of the domed regionshave three such indented bars, with some of the domed regions havingfour, five, six, seven, or even eight indented bars. The number ofindented bars can be confirmed using laser scan profiling (describedbelow). Using such laser scan profiling, it was found that in aparticular absorbent sheet according to an embodiment of our invention,there are, on average (mean), about six indented bars per domed region.

Without being limited by theory, we believe that the indented bars seenin the absorbent sheets shown in FIGS. 4A-4E and 5 are formed when theweb is transferred onto a structuring fabric with the configurationsdescribed herein during a papermaking process as described herein.Specifically, when a speed differential is used for creping the web asit is transferred onto the structuring fabric, the web “plows” onto theknuckles of the structuring fabric and into the pockets between theknuckles. As a result, folds are created in the structure of the web,particularly in the areas of the web that are moved into the pockets ofthe structuring fabric. An indented bar is thus formed between two ofsuch folds in the web. Because of the long MD pockets in the long warpyarn knuckle structuring fabrics described herein, the plowing/foldingeffect takes place multiple times over a portion of a web that spans apocket in the structuring fabric. Thus, multiple indented bars areformed in each of the domed regions of absorbent sheets made with thelong warp knuckle structuring fabrics described herein.

Again, without being limited by theory, we believe that the indentedbars in the domed regions may contribute to an increased softness thatis perceived in the absorbent sheets according to our invention.Specifically, the indented bars provide a more smooth, flat plane beingperceived when the absorbent sheet is touched, as compared to absorbentsheets having conventional domed regions. The difference in perceptionalplanes is illustrated in FIGS. 6A and 6B, which are drawings showingcross sections of an absorbent sheet 2000 according to our invention anda comparison sheet 3000, respectively. In absorbent sheet 2000, thedomed regions 2010 and 2020 include indented bars 2080, with ridgesbeing formed between the indented bars 2080 (the ridges/indentscorrespond to the folds in the web during the papermaking process asdescribed above). As a result of the small indented bars 2080 andplurality of ridges around the indented bars 2080, flat, smoothperceived planes P1 (marked with dotted lines in FIG. 6A) are formed.These flat, smooth planes P1 are sensed when the absorbent sheet 2000 istouched. We further believe that the users cannot detect the smalldiscontinuities of the indented bars 2080 in the surfaces of the domedregions 2010 and 2020, nor can users detect the short distance betweenthe domed regions 2010 and 2020. Thus, the absorbent sheet 2000 isperceived as having a smooth, soft surface. On the other hand, theperceived planes P2 have a more rounded shape with the conventionaldomes 3010 and 3020 in comparison sheet 3000, as shown in FIG. 6B, andthe conventional domes 3010 and 3020 are spaced apart. It is believedthat because the perceived planes P2 of the conventional domes 3010 and3020 are spaced a significant distance from each other, the comparisonsheet 3000 is perceived as less smooth and soft compared to theperceived planes P1 found in the domed regions 2010 and 2020 with theindented bars 2080.

Those skilled in the art will appreciate that, due to the nature of apapermaking process, not every domed region in an absorbent sheet willbe identical. Indeed, as noted above, domed regions of an absorbentsheet according to our invention might have different numbers ofindented bars. At the same time, a few of the domed regions observed inany particular absorbent sheet of our invention might not include anyindented bars. This will not affect the overall properties of theabsorbent sheet, however, as long as a majority of the domed regionsincludes the indented bars. Thus, when we refer to an absorbent sheet ashaving domed regions that include a plurality of indented bars, it willbe understood that that absorbent sheet might have a few domed regionswith no indented bars.

The lengths and depths of the indented bars in absorbent sheets, as wellas the lengths of the domed regions, can be determined from a surfaceprofile of a domed region that is made using laser scanning techniques,which are well known in the art. FIGS. 7A and 7B show laser scansprofiles across domed regions in two absorbent sheets according to ourinvention. The peaks of the laser scan profiles are the areas of thedomes that are adjacent to the indented bars, while the valleys of theprofiles represent the bottoms of the indented bars. Using such laserscan profiles, we have found that the indented bars extend to a depth ofabout 45 microns to about 160 microns below the tops of the adjacentareas of the domed regions. In a particular embodiment, the indentedbars extend an average (mean) of about 90 microns below the tops of theadjacent areas of the domed regions. In some embodiments, the domedregions extend a total of about 2.5 mm to about 3 mm in length in asubstantially MD of the absorbent sheets. Those skilled in the art willappreciate that such lengths in the MD of the domed regions are greaterthan the lengths of domed regions in conventional fabrics, and that thelong domed regions are at least partially the result of the long MDpockets in the structuring fabrics used to create the absorbent sheets,as discussed above. From the laser scan profiles, it can also be seenthat the indented bars were spaced about 0.5 mm apart along the lengthsof the domed regions in embodiments of our invention.

Further distinct features that can be seen in the absorbent sheets shownin FIGS. 4A-4E and 5 include the dome regions being bilaterallystaggered in the MD such that substantially continuous, stepped lines ofdomed regions extend in the MD of the sheets. For example, withreference again to FIG. 5, the domed region 1010 is positioned adjacentto the domed region 1020, with the two domed regions overlapping in aregion 1090. Similarly, the domed region 1020 overlaps domed region 1030in a region 1095. The bilaterally staggered domed regions 1010, 1020,and 1030 form a continuous, stepped line, substantially along the MD ofthe absorbent sheet 1000. Other domed regions form similar continuous,stepped lines in the MD.

We believe that the configuration of the elongated, bilaterallystaggered domed regions, in combination with the indented bars extendingacross the domed regions, results in the absorbent sheets having a morestable configuration. For example, the bilaterally staggered domedregions provides for a smooth planar surface on the Yankee side of theabsorbent sheets, which thereby results in a better distribution ofpressure points on the absorbent sheet (the Yankee side of an absorbentsheet being the side of the absorbent sheets that is opposite to the airside of the absorbent sheets that is drawn into the structuring fabricduring the papermaking process). In effect, the bilaterally staggereddomed regions act like long boards in the MD direction that cause theabsorbent sheet structure to lay flat. This effect, resulting from thecombination of bilaterally staggered domed regions and indented barswill, for example, cause a web to better lay down on the surface of aYankee dryer during a papermaking process, which results in betterabsorbent sheets.

Similar to the continuous lines of domed regions, substantiallycontinuous lines of connecting regions extend in a stepped manner alongthe MD of the absorbent sheet 1000. For example, connection region 1015,which runs substantially in the CD, is contiguous with connecting region1025, which runs substantially in the CD. Connecting region 1025 is alsocontiguous with connecting region 1035, which runs substantially in theMD. Similarly, connecting region 1015 is contiguous with connectingregion 1025 and connecting region 1055. In sum, the MD connectingregions are substantially longer than the CD connecting regions, suchthat lines of stepped, continuous connecting regions can be seen alongthe absorbent sheet.

As discussed above, the sizes of the domed regions and the connectingregions of an absorbent sheet generally correspond to the pocket andknuckle sizes in the structuring fabric used to produce the absorbentsheet. In this regard, we believe that the relative sizing of the domedand connecting regions contributes to the softness of absorbent sheetsmade with the fabric. We also believe that the softness is furtherimproved as a result of the substantially continuous lines of domedregions and connecting regions. In a particular embodiment of ourinvention, a distance in the CD across the domed regions is about 1.0mm, and a distance in the CD across the MD oriented connecting regionsis about 0.5 mm. Further, the overlap/touching regions between adjacentdomed regions in the substantially continuous lines are about 1.0 mm inlength along the MD. Such dimensions can be determined from a visualinspection of the absorbent sheets, or from a laser scan profile asdescribed above. An exceptionally soft absorbent sheet can be achievedwhen these dimensions are combined with the other features of ourinvention described herein.

In order to evaluate the properties of products according to ourinvention, absorbent sheets were made using Fabric 15 as shown FIG. 3Ein a papermaking machine having the general configuration shown in FIG.1 with a process as described above. For comparison, products were madeusing the shorter warp length knuckle Fabric 17 that is also shown inFIG. 3F under the same process conditions. Parameters used to producebasesheets for these trials are shown in TABLE 1.

TABLE 1 Process Variable Location Rate Furnish: 100% SHWK to Yankeelayer Stratified 65% SHWK 70% SSWK and 30% SHWKK 35% SSWK to middle andair layers Refiner Stock Vary as needed Temporary Wet Stock pumps 3 lb/TStrength Resin: FJ98 Starch: Static mixers 8 lb/T REDIBOND ™ 5330A CrepeRoll Load Crepe Roll 45 PLI Fabric Crepe Crepe Roll 20% Reel Crepe Reel 7% Calender Load Calender Stacks As needed Molding Box Vacuum MoldingBox Maximum

The basesheets were converted to produce two-ply glued tissueprototypes. TABLE 2 shows the converting specifications for the trials.

TABLE 2 Conversion Process Gluing Number of Plies  2 Roll Diameter 4.65in. Sheet Count 190 Sheet Length 4.09 in. Sheet Width 4.05 in. RollCompression 18-20% Emboss Process Following process of U.S. Pat. No.6,827,819 (which is incorporated by reference in its entirety) EmbossPattern Constant/Non-Varying

Sheets formed in the trials with Fabric 15 (i.e., a long warp knucklefabric) were found to be smoother and softer than the sheets formed inthe trials with Fabric 17 (i.e., a shorter warp knuckle fabric). Otherimportant properties of the sheets made with Fabric 15, such as caliperand bulk, were found to be very comparable to those properties of thesheets made with Fabric 17. Thus, it is clear that the basesheets madewith the long warp knuckle Fabric 15 could potentially be used to makeabsorbent products that are softer than absorbent products with theshorter warp knuckle Fabric 17 without the reduction of other importantproperties of the absorbent products.

As described in the aforementioned fabric characterization patents, theplanar volumetric index (PVI) is a useful parameter for characterizing astructuring fabric. The PVI for a structuring fabric is calculated asthe contact area ratio (CAR) multiplied by the effective pocket volume(EPV) multiplied by one hundred, where the EPV is the product of thepocket area estimate (PA) and the measured pocket depth. The pocketdepth is most accurately calculated by measuring the caliper of ahandsheet formed on the structuring fabric in a laboratory, and thencorrelating the measured caliper to the pocket depth. And, unlessotherwise noted, all of the PVI-related parameters described herein weredetermined using this handsheet caliper measuring method. Further, anon-rectangular, parallelogram PVI is calculated as the contact arearatio (CAR) multiplied by the effective pocket volume (EPV) multipliedby one hundred, where the CAR and EPV are calculated using anon-rectangular, parallelogram unit cell area calculation. Inembodiments of our invention, the contact area of the structuring longwarp knuckle fabric varies between about 25% to about 35% and the pocketdepth varies between about 100 microns to about 600 microns, with thePVI thereby varying accordingly.

Another useful parameter for characterizing a structuring fabric relatedto the PVI is a planar volumetric density index (PVDI) of thestructuring fabric. The PVDI of a structuring fabric is defined as thePVI multiplied by pocket density. Note that in embodiments of ourinvention, the pocket density varies between about 10 cm−2 to about 47cm−2. Yet another useful parameter of a structuring fabric can bedeveloped by multiplying the PVDI by the ratio of the length and widthof the knuckles of the fabric, thereby providing a PVDI-knuckle ratio(PVDI-KR). For example, a PVDI-KR for a long warp knuckle structuringfabric as described herein would be the PVDI of the structuring fabricmultiplied by the ratio of warp knuckles length in the MD to the warpknuckles width in the CD. As is apparent from the variables used tocalculate the PVDI and PVDI-KR, these parameters take into accountimportant aspects of a structuring fabric (including percentage ofcontact area, pocket density, and pocket depth) that affect shapes ofpaper products made using the structuring fabric, and, hence, the PVDIand PVDI-KR may be indicative of the properties of the paper productssuch as softness and absorbency.

The PVI, PVDI, PVDI-KR, and other characteristics were determined forthree long warp knuckle structuring fabrics according to embodiments ofour invention, with the results being shown as Fabrics 18-20 in FIG. 8.For comparison, the PVI, PVDI, PVDI-KR, and other characteristics werealso determined for a shorter warp knuckle structuring fabric, as isshown as Fabric 21 in FIG. 8. Notably, the PVDI-KRs for Fabrics 18-20are about 43 to about 50, which are significantly greater than thePVDI-KR of 16.7 for Fabric 21.

Fabrics 18-21 were used to produce absorbent sheets, and characteristicsof the absorbent sheets were determined, as shown in FIG. 9. Thecharacteristics shown in FIG. 9 were determined using the sametechniques that are described in the aforementioned fabriccharacterization patents. In this regard, the determinations of theinterconnecting regions correspond to the warp knuckles on thestructuring fabric, and the dome regions correspond to the pockets ofthe structuring fabric. Also, it could again be seen that the sheetsmade from the long warp knuckle Fabrics 18-20 have multiple indentedbars in each dome region. On the other hand, the domed regions of theabsorbent sheet formed from the shorter warp knuckle Fabric 21 had, atmost, one indented bar, and many of the domed regions did not have anyindented bars at all.

The sensory softness was determined for the absorbent sheets shown inFIG. 9. Sensory softness is a measure of the perceived softness of apaper product as determined by trained evaluators using standardizedtesting techniques. More specifically, sensory softness is measured byevaluators experienced with determining the softness, with theevaluators following specific techniques for grasping the paper andascertaining a perceived softness of the paper. The higher the sensorysoftness number, the higher the perceived softness. In the case of thesheets made from Fabrics 18-20, it was found that the absorbent sheetsmade with Fabrics 18-20 were 0.2 to 0.3 softness units higher than theabsorbent sheets made with Fabric 21. This difference is outstanding.Moreover, the sensory softness was found to correlate with the PVDI-KRof the fabrics. That is, the higher the PVDI-KR of the structuringfabric, the higher the sensory softness number that was achieved. Thus,we believe that PVDI-KR is a good indicator of the softness that can beachieved in a paper product made with a process using a structuringfabric, with a higher PVDI-KR structuring fabric producing a softerproduct.

FIGS. 10A through 10D show characteristics of further long-warp knuckleFabrics 22-41 according to various embodiments of our invention,including the PVI, PVDI, and PVDI-KR for each of the fabrics. Notably,these structuring fabrics have a wider range of characteristics than thestructuring fabrics described above. For example, contact lengths of thewarp knuckles of Fabrics 22-41 ranged from about 2.2 mm to about 5.6 mm.In further embodiments of our invention, however, the contact lengths ofthe warp knuckles may range from about 2.2 mm to about 7.5 mm. Note thatin the case of Fabrics 22-37 and 41, the pocket depths were determinedby forming a handsheet on the fabrics and then determining the size ofdomes on the handsheet (the size of the domes corresponding to the sizeof the pockets, as described above). The pocket depths for Fabrics 38-40were determined using techniques set forth in the aforementioned fabriccharacterization patents.

Further trials were conducted to evaluate properties of absorbent sheetsaccording to embodiments of our invention. In these trials, the Fabrics27 and 38 were used. For these trials, a papermaking machine having thegeneral configuration shown in FIG. 1 was used with a process asdescribed above. Parameters used to produce the basesheets for thesetrials are shown in TABLE 3. Note that an indication of a varying ratemeans that the process variable was varied in different trial runs.

TABLE 3 Process Variable Location Rate Furnish Lighthouse HomogeneousRecycled Fibers Refiner Stock No load (22 hp) Temporary Wet N/A 0Strength Resin Starch: Static mixers As needed REDIBOND ™ 5330A CrepeRoll Load Crepe Roll 30-40 PLI Fabric Crepe Crepe Roll varying 25%-35%Reel Crepe Reel 2-4% Molding Box Vacuum Molding Box Maximum

The basesheets in these trials were converted into unembossed,single-ply rolls.

Pictures of the absorbent sheets made with Fabric 27 are shown in FIGS.11A-11E and pictures of the absorbent sheets made with Fabric 38 areshown in FIGS. 12A-12E. As is apparent from FIGS. 11A-11E and 12A-12E,the domed regions of the absorbent sheets included a plurality ofindented bars like the absorbent sheets described above. And, also likethe absorbent sheets described above, the absorbent sheets made withFabrics 27 and 38 include bilaterally staggered domed regions thatresult in substantially continuous, stepped lines in the MD of theabsorbent sheets, and substantially continuous, stepped connectingregions between the domed regions.

The profiles of the domed regions in the basesheets made from Fabrics 27and 38 were determined using laser scanning, in the same manner that theprofiles were determined in the absorbent sheets described above. It wasfound that the domed regions in the basesheets made with Fabric 27 had 4to 7 indented bars, with there being an average (mean) of 5.2 indentedbars per domed region. The indented bars of domed regions extended fromabout 132 to about 274 microns below the tops of adjacent areas of thedomed regions, with an average (mean) depth of about 190 microns.Further, the domed regions extended about 4.5 mm in the MD of thebasesheets.

The domed regions in the basesheets made with Fabric 38 had 4 to 8indented bars, with there being an average (mean) of 6.29 indented barsper domed region. The indented bars of domed regions in the basesheetsmade with Fabric 38 extended from about 46 to about 159 microns belowthe tops of adjacent areas of the domed regions, with an average (mean)depth of about 88 microns. Further, the domed regions extended about 3mm in the MD of the basesheets.

Because the extended MD direction domed regions in the basesheets madewith Fabrics 27 and 38 include a plurality of indented bars, it followsthat the basesheets will have similar beneficial properties stemmingfrom the configuration of the domed regions as the absorbent sheetsdescribed above. For example, the basesheets made with Fabrics 27 and 38will be softer to the touch compared to basesheets made with fabrics nothaving long warp knuckles.

Other properties of the basesheets made with Fabrics 27 and 38 werecompared to the properties of basesheets made with shorter knucklefabrics. Specifically, the caliper and pocket depth were compared foruncalendered basesheets made with the different fabrics. The caliper wasmeasured using standard techniques that are well known in the art. Itwas found that the caliper of the basesheets made with Fabric 27 variedfrom about 80 mils/8 sheets to about 110 mils/8 sheets, while thebasesheets made with Fabric 38 varied from about 80 mils/8 sheets toabout 90 mils/8 sheets. Both of these ranges of caliper are verycomparable, if not better than, the about 60 to about 93 mils/8 sheetscaliper that was found in the basesheets made with shorter warp yarnknuckle fabrics under similar process conditions.

The depths of the domed regions were measured using a topographicalprofile scan of the air side (i.e, the side of the basesheets thatcontacts the structuring fabric during the papermaking process) of thebasesheets to determine the depths of the lowest points of domed regionsbelow the Yankee side surface. The depths of the domed regions in thebasesheets made using Fabric 27 ranged from about 500 microns to about675 microns, while the depths of the domed regions in the basesheetsmade using Fabric 38 ranged from about 400 microns to about 475 microns.These domed regions were comparable to, if not greater than, the depthsof the domed regions in basesheets made from the structuring fabricshaving shorter warp yarn knuckles. This comparability of the depths ofdomed regions is consistent with the finding that the basesheets madewith the long warp yarn structuring fabrics having comparable caliper tothe basesheets made with the shorter warp yarn structuring fabricsinasmuch as the depth of domed regions is directly related to thecaliper of an absorbent sheet.

The characteristics of further long warp yarn knuckle fabrics accordingto our invention are labeled as Fabrics 42-44 in FIG. 13. Also shown inFIG. 13 is a conventional Fabric 45 that does not include long warp yarnknuckles. Further characteristics of Fabric 42 are given in FIG. 14,which shows the profile along one of the warp yarns of the fabric. Ascan be seen in these figures, Fabric 42 has several notable features inaddition to including long warp yarn knuckles. One feature is that thepockets are long and deep, as reflected in the PVI related parametersindicated in FIG. 13. As can also be seen in the pressure imprint ofFabric 42 shown in FIG. 13, another notable feature of this fabric isthat the CD yarns are entirely located below the plane of the knucklesin the MD yarns such that there are no CD knuckles at the top surface ofthe fabric. Because there are no CD knuckles, there is a gradual slopeto the warp yarns in the z-direction, the details of which are shown inthe profile scan in FIG. 14. As indicated in this figure, the warp yarnshave a slope of about 200 μm/mm from the lowest point where the warpyarns pass under a CD yarn to the top of the adjacent warp knuckle. Moregenerally speaking, the warp yarns are angled from about 11 degreesrelative to a plane that Fabric moves along during the crepingoperation. It is believed that this gradual slope of the warp yarnsallows the fibers in a web being pressed to Fabric 42 to only slightlypile up on the sloped portion of the warp yarn before being some of thefibers slip up over the top of the adjacent knuckle. The gradual slopeof the warp yarns in Fabric 42 thereby creates less of an abrupt stopfor the fibers of the web and less densification of the fibers comparedto other fabrics where the warp yarns have a steeper slope that iscontacted by the web.

Fabrics 42 and 43 both have higher PVDI-KR values, and these values inconjunction with the PVDI-KR values of the other structuring fabricsdescribed herein are generally indicative of the range of PVDI-KR valuesthat can be found in embodiments of our invention. Further, structuringfabrics with even higher PVDI-KR values could also be used, for example,up to about 250.

In order to evaluate the properties of Fabric 42, a series of trials wasconducted with this fabric and with Fabric 45 for comparison. In thesetrials, a papermaking machine having the general configuration shown inFIG. 1 was used to form absorbent towel basesheets. The non-TAD processdescribed generally above and specifically set forth in theaforementioned '563 patent was used, wherein the web was dewatered tothe point that it had a consistency of about 40 to about 43 percent whentransferred onto the top side of the structuring fabric (i.e., Fabric 42or 45) at the creping nip. Other particular parameters of these trailswere as shown in TABLE 4.

TABLE 4 Process Variable Location Rate Furnish Premium (“P”): Stratified70% NSWK/30% Eucalyptus. or Non-premium (“NP”): 70% SSWK/30% SHWKRefiner Stock Varies WSR/CMC Static Mixer 20/3.2 (#/T total) DebonderAddition None None Crepe Roll Load Crepe Roll 40-60 PLI Fabric CrepeCrepe Roll As indicated in tables below Reel Crepe Reel 2% Molding BoxMolding Box Varying between Vacuum full and zero

The properties of the basesheets made in these trials with Fabrics 42and 45 are shown in TABLES 5-9. The testing protocols used to determinethe properties indicated in TABLES 5-9 can be found in U.S. Pat. Nos.7,399,378 and 8,409,404, which are incorporated herein by reference intheir entirety. An indication of “N/C” indicates that a property was notcalculated for a particular trial.

TABLE 5 Trial 1 2 3 4 5 6 7 8 9 10 11 Fabric 45 45 45 45 45 45 45 45 4545 45 Fabric Crepe (%) 3 3 5 5 8 8 15 15 20 20 30 Furnish NP NP NP NP NPNP NP NP NP NP NP Caliper 63.18 62.93 68.20 67.35 77.98 77.53 84.9888.43 92.38 90.55 99.38 (mils/8 sheets) Basis Weight 15.17 15.42 15.3315.38 15.31 15.34 15.59 15.28 15.85 15.50 15.47 (lb/3000 ft²) MD Tensile1590 1554 1353 1639 1573 1498 1387 1445 1401 1145 1119 (g/3 in) MDStretch (%) 8.1 8.9 9.8 10.3 13.1 12.4 20.1 18.8 24.2 24.5 33.9 CDTensile 1393 1382 1294 1420 1393 1428 1401 1347 1231 1200 1272 (g/3 in)CD Stretch (%) 4.5 4.8 4.5 4.7 4.9 4.9 6.1 7.1 6.1 6.0 7.0 Wet Tensile378.42 377.31 396.72 426.79 392.27 399.08 389.35 359.39 381.15 383.22388.66 Finch Cured-CD (g/3 in) SAT Capacity 303.76 316.09 329.09 339.94369.38 362.64 421.02 415.43 454.08 420.03 486.14 (g/m²) GM Tensile 14881466 1323 1526 1481 1462 1394 1395 1313 1172 1193 (g/3 in) GM Break254.08 227.72 198.96 220.16 186.53 189.30 130.30 116.76 108.50 97.1078.67 Modulus (g/%) SAT Time (s) N/C N/C N/C N/C 47.3 47.3 N/C N/C N/CN/C N/C Tensile Dry Ratio 1.14 1.12 1.05 1.15 1.13 1.05 0.99 1.07 1.140.95 0.88 SAT Rate g/s^(0.5) N/C N/C N/C N/C 0.1233 0.1073 N/C N/C N/CN/C N/C Tensile Total 2983 2937 2647 3059 2967 2926 2788 2792 2632 23452391 Dry (g/3 in) Tensile Wet/ 0.27 0.27 0.31 0.30 0.28 0.28 0.28 0.270.31 0.32 0.31 Dry CD Basis Weight 1.147 1.166 1.159 1.163 1.158 1.1601.179 1.156 1.198 1.172 1.170 Raw Wt (g) T.E.A. CD 0.386 0.388 0.3700.439 0.448 0.434 0.505 0.537 0.472 0.445 0.521 (mm-g/mm²) T.E.A. MD0.693 0.759 0.733 0.911 1.043 0.982 1.461 1.400 1.700 1.431 1.993(mm-g/mm²) CD Break 314.12 292.46 274.57 305.26 283.37 297.78 240.35171.68 200.07 199.94 190.52 Modulus (g/%) MD Break 205.51 177.30 144.18158.79 122.78 120.33 70.64 79.40 58.84 47.16 32.48 Modulus (g/%)

TABLE 6 Trial 12 13 14 15 16 17 18 19 20 21 22 Fabric 45 45 42 42 42 4242 42 42 42 42 Fabric Crepe (%) 30 40 5 5 8 8 12 12 15 15 17.5 FurnishNP NP NP NP NP NP NP NP NP NP NP Caliper 100.03 103.35 104.73 101.30103.33 106.95 112.40 111.78 115.83 124.73 118.75 (mils/8 sheets) BasisWeight 15.48 15.89 15.55 15.71 15.16 15.77 15.52 14.99 15.62 15.46 15.54(lb/3000 ft²) MD Tensile 1191 1310 1346 1404 1217 1381 1205 1118 11391193 1100 (g/3 in) MD Stretch (%) 33.8 42.1 9.4 9.2 11.9 13.6 16.3 16.818.5 18.6 22.5 CD Tensile 1216 1091 1221 1171 1164 1305 1229 1187 12081273 1186 (g/3 in) CD Stretch (%) 6.4 9.7 6.7 6.5 7.6 6.7 8.2 9.0 8.97.3 8.4 Wet Tensile 375.14 333.25 384.19 341.28 334.01 391.05 383.33356.94 367.40 386.18 398.40 Finch Cured-CD (g/3 in) SAT Capacity 482.86N/C 421.51 426.61 457.53 455.88 479.24 509.33 533.67 491.24 515.91(g/m²) GM Tensile 1203 1195 1282 1283 1191 1343 1217 1152 1173 1232 1142(g/3 in) GM Break 84.14 59.92 162.90 168.66 128.36 141.14 105.49 93.5694.07 106.55 84.05 Modulus (g/%) SAT Time (s) N/C N/C 58.5 55.9 48.462.4 46.9 46.6 43.8 39.6 40.8 Tensile Dry Ratio 0.98 1.20 1.10 1.20 1.051.06 0.98 0.94 0.94 0.94 0.93 SAT Rate g/s^(0.5) N/C N/C 0.1240 0.12500.1460 0.1330 0.1463 0.1703 0.1787 0.1653 0.1747 Tensile Total 2406 24012568 2576 2382 2686 2434 2305 2347 2466 2286 Dry (g/3 in) Tensile Wet/0.31 0.31 0.31 0.29 0.29 0.30 0.31 0.30 0.30 0.30 0.34 Dry CD BasisWeight 1.170 1.202 1.176 1.188 1.146 1.193 1.173 1.134 1.181 1.169 1.175Raw Wt (g) T.E.A. CD 0.493 0.614 0.486 0.458 0.504 0.520 0.561 0.5860.600 0.527 0.555 (mm-g/mm²) T.E.A. MD 2.102 2.729 0.854 0.875 0.9651.147 1.262 1.191 1.326 1.397 1.476 (mm-g/mm²) CD Break 200.28 115.03186.61 185.12 160.98 196.28 149.84 131.23 142.85 172.21 141.16 Modulus(g/%) MD Break 35.35 31.21 142.20 153.67 102.35 101.49 74.26 66.71 61.9565.93 50.04 Modulus (g/%)

TABLE 7 Trial 23 24 25 26 27 28 29 30 31 32 33 Fabric 42 42 42 42 42 4242 42 42 42 42 Fabric Crepe (%) 17.5 20 20 25 25 3 3 5 5 8 8 Furnish NPNP NP NP NP P P P P P P Caliper 120.55 125.73 119.30 119.08 117.58 88.6080.00 102.35 99.75 106.93 113.50 (mils/8 sheets) Basis Weight 15.3615.46 15.54 15.71 15.56 15.38 15.73 15.46 15.67 15.73 15.59 (lb/3000ft²) MD Tensile 1156 1168 1218 1098 1164 1545 1481 1255 1336 1305 1266(g/3 in) MD Stretch (%) 22.7 24.9 24.5 28.8 29.6 8.6 8.3 11.5 11.5 13.513.4 CD Tensile 1230 1137 1220 1135 1160 1353 1263 1171 1194 1202 1145(g/3 in) CD Stretch (%) 9.5 9.8 10.1 9.0 8.7 6.6 6.6 7.4 7.7 7.1 8.4 WetTensile 389.77 355.26 412.54 353.38 358.26 394.94 400.23 365.83 380.93404.07 342.44 Finch Cured-CD (g/3 in) SAT Capacity 549.13 566.40 487.13550.61 541.90 366.91 380.56 438.45 424.80 462.79 454.57 (g/m²) GMTensile 1192 1152 1219 1116 1162 1446 1368 1212 1263 1252 1204 (g/3 in)GM Break 79.01 75.16 77.59 69.14 71.02 189.84 187.19 134.80 135.76127.34 114.64 Modulus (g/%) SAT Time (s) 46.2 82.5 61.1 49.6 46.0 59.861.4 60.9 61.3 63.5 58.6 Tensile Dry Ratio 0.94 1.03 1.00 0.97 1.00 1.141.17 1.07 1.12 1.09 1.11 SAT Rate g/s^(0.5) 0.1747 0.1410 0.1297 0.15930.1613 0.0753 0.0917 0.1230 0.1123 0.1313 0.1263 Tensile Total 2386 23052438 2233 2324 2898 2744 2426 2530 2506 2411 Dry (g/3 in) Tensile Wet/0.32 0.31 0.34 0.31 0.31 0.29 0.32 0.31 0.32 0.34 0.30 Dry CD BasisWeight 1.162 1.169 1.175 1.188 1.176 1.163 1.189 1.169 1.185 1.190 1.179Raw Wt (g) T.E.A. CD 0.638 0.647 0.652 0.610 0.613 0.503 0.492 0.5050.533 0.501 0.514 (mm-g/mm²) T.E.A. MD 1.520 1.661 1.710 1.849 1.9650.843 0.784 0.924 0.965 1.090 1.054 (mm-g/mm²) CD Break 121.69 118.88118.90 125.56 129.39 202.35 193.60 160.78 156.90 165.68 136.75 Modulus(g/%) MD Break 51.31 47.52 50.63 38.07 38.99 178.10 181.00 113.03 117.4797.87 96.10 Modulus (g/%)

TABLE 8 Trial 34 35 36 37 38 39 40 41 42 43 Fabric 42 42 42 42 42 42 4242 42 42 Fabric Crepe (%) 12 12 15 15 17.5 17.5 20 20 25 25 Furnish P PP P P P P P P P Caliper (mils/8 sheets) 106.90 111.85 126.78 113.55116.38 117.43 124.28 118.38 127.15 123.45 Basis Weight (lb/3000 ft²)15.25 15.52 15.28 15.56 15.22 15.13 15.27 15.36 15.73 15.66 MD Tensile(g/3 in) 1285 1362 1151 1099 1163 1246 1311 1268 1126 1114 MD Stretch(%) 18.0 17.8 21.4 20.1 24.2 21.7 24.1 25.6 30.0 29.5 CD Tensile (g/3in) 1263 1291 1105 1239 1309 1156 1279 1188 1153 1215 CD Stretch (%) 8.98.2 9.8 8.9 9.8 10.1 10.4 10.4 11.3 10.8 Wet Tensile Finch 361.36 377.41363.51 382.17 382.19 340.60 364.82 370.56 380.50 371.50 Cured-CD (g/3in) SAT Capacity (g/m²) 540.09 498.97 502.43 514.43 535.48 558.67 585.81568.05 553.90 551.76 GM Tensile (g/3 in) 1274 1326 1128 1167 1234 12001295 1227 1139 1163 GM Break Modulus (g/%) 101.68 109.99 78.18 87.0180.40 82.55 84.45 76.02 62.29 64.93 SAT Time (s) 37.5 42.7 55.4 47.350.2 51.4 45.1 44.3 66.6 53.5 Tensile Dry Ratio 1.02 1.06 1.04 0.89 0.891.08 1.03 1.07 0.98 0.92 SAT Rate g/s^(0.5) 0.1637 0.1557 0.1480 0.15700.1623 0.1553 0.1753 0.1783 0.1453 0.1483 Tensile Total Dry (g/3 in)2548 2652 2257 2338 2472 2402 2589 2456 2279 2328 Tensile Wet/Dry CD0.29 0.29 0.33 0.31 0.29 0.29 0.29 0.31 0.33 0.31 Basis Weight Raw Wt(g) 1.153 1.173 1.156 1.177 1.151 1.144 1.155 1.161 1.189 1.184 T.E.A.CD (mm-g/mm²) 0.627 0.625 0.566 0.600 0.676 0.617 0.695 0.659 0.6910.703 T.E.A. MD (mm-g/mm²) 1.393 1.474 1.421 1.371 1.592 1.599 1.8251.803 1.928 1.907 CD Break Modulus (g/%) 145.26 158.25 111.51 137.62134.41 116.31 128.13 116.00 101.44 113.29 MD Break Modulus (g/%) 71.1876.45 54.81 55.01 48.09 58.59 55.66 49.82 38.25 37.21

TABLE 9 Trial 44 45 46 47 Fabric 42 42 42 42 Fabric Crepe (%) 30 30 3535 Furnish P P P P Caliper (mils/8 sheets) 126.38 124.25 122.83 123.23Basis Weight 15.75 15.47 15.35 14.46 (lb/3000 ft²) MD Tensile (g/3 in)1126 1118 1157 1097 MD Stretch (%) 35.0 35.2 33.9 34.4 CD Tensile (g/3in) 1050 1090 1083 1097 CD Stretch (%) 11.2 10.2 10.6 10.8 Wet TensileFinch 366.41 398.97 363.35 377.73 Cured-CD (g/3 in) SAT Capacity (g/m²)549.30 522.16 544.69 533.02 GM Tensile (g/3 in) 1088 1104 1119 1097 GMBreak Modulus 54.29 56.95 59.34 56.65 (g/%) SAT Time (s) 51.3 66.1 58.453.2 Tensile Dry Ratio 1.07 1.03 1.07 1.00 SAT Rate g/s^(0.5) 0.14570.1330 0.1543 0.1547 Tensile Total Dry 2176 2208 2240 2194 (g/3 in)Tensile Wet/Dry CD 0.35 0.37 0.34 0.34 Basis Weight Raw 1.191 1.1701.161 1.093 Wt (g) T.E.A. CD (mm-g/mm²) 0.625 0.628 0.639 0.623 T.E.A.MD (mm-g/mm²) 2.094 2.062 2.049 2.074 CD Break Modulus 90.54 103.85103.20 100.59 (g/%) MD Break Modulus 32.55 31.23 34.12 31.90 (g/%)

The results of the trials shown in TABLES 5-9 demonstrate that Fabric 42can be used to produce basesheets having an outstanding combination ofproperties, particularly caliper and absorbency. Without being bound bytheory, we believe that these results stem, in part, from theconfiguration of knuckles and pockets in Fabric 42. Specifically, theconfiguration of Fabric 42 provides for a highly efficient crepingoperation due to the aspect ratio of the pockets (i.e., the length ofthe pockets in the MD versus the width of the pockets in the CD), thepockets being deep, and the pockets being formed in long, nearcontinuous lines in the MD. These properties of the pockets allow forgreat fiber “mobility,” which is a condition where the wet compressedweb is subjected to mechanical forces that create localized basis weightmovement. Moreover, during the creping process, the cellulose fibers inthe web are subjected to various localized forces (e.g., pushed, pulled,bent, delaminated), and subsequently become more separated from eachother. In other words, the fibers become de-bonded and result in a lowermodulus for the product. The web therefore has better vacuum“moldability,” which leads to greater caliper and a more open structurethat provides for greater absorption.

The fiber mobility provided for with the pocket configuration of Fabric42 can be seen in the results shown in FIGS. 15 and 16. These figurescompare the caliper, SAT capacity, and void volume at the various crepelevels used in the trials. FIGS. 15 and 16 show that, even in the trialswith Fabric 42 where no vacuum molding was used, the caliper and SATcapacity increased with the increasing fabric crepe level. As there wasno vacuum molding, it follows that these increases in caliper and SATcapacity are directly related to fiber mobility in Fabric 42. FIGS. 15and 16 also demonstrate that a high amount of caliper and SAT capacityare achieved using Fabric 42—in the trials where vacuum molding is used,at each creping level the caliper and SAT capacity of the basesheetsmade with Fabric 42 were much greater than the caliper and SAT capacityof the basesheets made with Fabric 45.

The fiber moldability provided by Fabric 42 can also be seen in theresults shown in FIGS. 15 and 16. Specifically, the differences betweenthe caliper and SAT capacity in the trials with no vacuum molding andthe trials with vacuum molding demonstrates that the fibers in the webare highly moldable on Fabric 42. As will be discussed below, vacuummolding draws out the fibers in the regions of the web formed in thepockets of Fiber 42.

The large fiber moldability means that the fibers are highly drawn outin this molding operation, which leads to the increased caliper and SATcapacity in the resulting product.

FIG. 19 also evidences that greater fiber mobility is achieved withFabric 42 by comparing the void volume of the basesheets from the trialsat the fabric crepe levels. The absorbency of a sheet is directlyrelated to void volume, which is essentially a measure of the spacebetween the cellulose fibers. Void volume is measured by the procedureset forth in the aforementioned U.S. Pat. No. 7,399,378. As shown inFIG. 19, the void volume increased with the increasing fabric crepe inthe trials using Fabric 42 where no vacuum molding was used. Thisindicates that the cellulose fibers were more separated from each other(i.e., de-bonded, with a lower resulting modulus) at each fabric crepelevel in order to produce the additional void volume. FIG. 19 furtherdemonstrates that, when vacuum molding is used, Fabric 42 producesbasesheets with more void volume than the conventional Fabric 45 at eachfabric crepe level.

The fiber mobility when using Fabric 42 can also be seen in FIGS. 20(a),20(b), 21(a), and 21(b), which are soft x-ray images of basesheets madeusing Fabric 42. As will be appreciated by those skilled in the art,soft x-ray imaging is a high-resolution technique that can be used forgauging mass uniformity in paper. The basesheets in FIGS. 20(a) and20(b) where made with an 8 percent fabric crepe, whereas the basesheetsin FIGS. 21(a) and 21(b) were made with a 25 percent fabric crepe. FIGS.20(a) and 21(a) show fiber movement at a more “macro” level, with theimages showing an area of 26.5 mm by 21.2 mm. Wave-like patterns of lessmass (corresponding to the lighter regions in the images) can be seenwith the higher fabric crepe (FIG. 21(a)), but regions of less mass arenot readily seen with the lower fabric crepe (FIG. 20(a)). FIGS. 20(b)and 21(b) show the fiber movement at a more “micro” level, with theimages showing an area of 13.2 mm by 10.6 mm. The cellulose fibers canclearly be seen as more distanced from each other and pulled apart withthe higher fabric crepe (FIG. 21(b)) than with the lower fiber crepe(FIG. 20(b)). Collectively, the soft x-ray images further confirm thatFabric 42 provides for great fiber mobility with the higher localizedmass movement being seen at the higher fabric crepe level than at thelower fabric crepe level.

FIGS. 17 and 18, and also FIG. 19, show the results of the trials interms of the furnish. Specifically, these figures show that Fabric 42can produce comparable amounts of caliper, SAT capacity, and void volumewhen using the non-premium furnish as with the premium furnish. This isa very beneficial result as it demonstrates that the Fabric 42 canachieve outstanding results with a lower cost, non-premium furnish.

Because Fabric 42 has extra-long warp yarn knuckles, as with the otherextra-long warp yarn knuckle fabrics described above, the products madewith Fabric 42 may have multiple indented bars extending in a CDdirection. The indented bars are again the result of folds being createdin the areas of the web that are moved into the pockets of thestructuring fabric. In the case of Fabric 42, it is believed that theaspect ratio of the length of the knuckles and the length across thepocket even further enhances the formation of the folds/indented bars.This is because the web is semi-restrained on the long warp knuckleswhile being more mobile within the pockets of Fabric 42. The result thatthe web can buckle or fold at multiple places along each pocket, whichin turn leads to the CD indented bars seen in the products.

The indented bars formed in absorbent sheets made from Fabric 42 can beseen in FIGS. 22(a) through 22(e). These figures are images of theair-side of products made with Fabric 42 at different fabric crepinglevels but with no vacuum molding. The MD is in the vertical directionin all of these figures. Notably, instead of having sharply defined domeregions like the products described above, the products in FIGS. 22(a)through 22(e) are characterized by having parallel and near-continuouslines of projected regions substantially extending in the MD, with eachof the extended projected regions including a plurality of indented barsextending across the projected regions in a substantially CD of theabsorbent sheet. These projected rejections correspond to lines ofpockets extending in the MD of Fabric 42. Between the projected regionsare connecting regions that also extend substantially in the MD. Theconnecting regions correspond to the long warp yarn knuckles of Fabric42.

The product in FIG. 22(a) was made with a fabric crepe of 25%. In thisproduct, the indented bars are very distinct. It is believed that thispattern of indented bars are the result of the fiber network on Fabric42 experiencing a wide range of forces during the creping process,including in-plane compression, tension, bending, and buckling. All ofthese forces will contribute to the fiber mobility and fibermoldability, as discussed above. And, as a result of the near continuousnature of the projected regions extending in the MD, the enhanced fibermobility and fiber moldability can take place in a near continuousmanner along the MD.

FIGS. 22(b) through 22(e) show the configuration of products with lessfabric creping as compared to the product shown in FIG. 22(a). In FIG.22(b), the fabric crepe level used to form the depicted product was 15%,in FIG. 22(c) the fabric crepe level was 10%, in FIG. 22(d) the fabriccrepe level was 8%, and in FIG. 22(e) the fabric crepe level was 3%. Aswould be expected, the amplitude of the folds/indented bars can be seento decrease with the decreasing fabric crepe level. However, it isnotable that the frequency of the indented bars remains about the samethrough the fabric crepe levels. This indicates that the web isbuckling/folding in the same locations relative to the knuckles andpockets in Fabric 42 regardless of fabric crepe level being used. Thus,beneficial properties stemming from the formation of folds/indented barscan be found even at lower fabric crepe levels.

In sum, FIGS. 22(a) through 22(e) show that the high pocket aspect ratioof Fabric 42 has the ability to uniformly exert decompacting energy tothe web such that fiber mobility and fiber moldability are promoted overa wide fabric creping range. And, this fiber mobility and fibermoldability is a very significant factor in the outstanding properties,such as caliper and SAT capacity, found in the absorbent sheets madewith Fabric 42.

FIGS. 23(a) through 24(b) are scanning electron microscopy images of theair sides of a product made with Fabric 42 (FIGS. 23(a) and 24(a)) and acomparison product made with Fabric 45 (FIGS. 23(b) and 24(b)). In thesecases, the products were made with 30% fabric crepe and maximum vacuummolding. The center regions of the images in FIGS. 23(a) and 23(b) showareas made in the pockets of the respective fabrics, with areassurrounding the center regions corresponding to regions formed onknuckles of the respective fabrics. The cross sections shown in FIGS.24(a) and 24(b) extend substantially along the MD, with an extendedprojected region of the Fabric 42 product being seen in FIG. 24(a) andwith multiple domes (as formed in multiple pockets) being seen in theFabric 45 product shown in FIG. 24(b). It can very clearly be seen thatthe fibers in the product made with Fabric 42 are much less denselypacked than the cellulose fibers in the product made with Fabric 45.That is, the center dome regions in the Fabric 45 product are highlydense—as dense, if not more dense, than the connecting regionsurrounding the pocket region in the Fabric 42 product. Moreover, FIGS.24(a) and 24(b) show the fibers to be much looser, i.e., less dense, inthe Fabric 42 product than in the Fabric 45 product, with distinctfibers springing out from the Fabric 42 product structure in FIG. 24(a).FIGS. 23(a) through 24(b) thereby further confirm that that Fabric 42provides for a large amount of fiber mobility and fiber moldabilitycreping process, which in turn results in regions of significantlyreduced density in the absorbent sheet products made with the fabric.The reduced density regions provide for greater absorbency in theproducts. Further, the reduced density regions provide for more caliperas the sheet becomes more “puffed out” in the reduced density regions.Still further, the puffy, less dense regions will result in the productfeeling softer to the touch.

Further trials were conducted using Fabric 42 to evaluate properties ofconverted towel products according to embodiments of our invention. Forthese trials, the same conditions were used as in the trials describedin conjunction with TABLES 4 and 5. The basesheets were then convertedto two-ply paper towel. TABLE 10 shows the converting specifications forthese trials. Properties of products made in these trials are shown inTABLES 11-13.

TABLE 10 Conversion Process Gluing Number of Plies 2 Roll DiameterVarying Sheet Count 60 Sheet Length 10.4 Sheet Width 11 in. RollCompression 6-12% Emboss Process Following process of U.S. Pat. No.6,827,819 with the embossing pattern shown in U.S. Pat. Design No.D504,236 (which is incorporated by reference in its entirety) EmbossPattern Constant/Non-Varying

TABLE 11 Trial 1 2 3 4 5 6 7 8 9 10 Fabric 42 42 42 42 42 42 42 42 42 42Fabric Crepe (%) 3 5 8 12 15 17.5 20 25 30 35 Furnish P P P P P P P P PP Basis Weight (lbs/ream) 31.57 31.39 31.27 31.12 31.21 30.94 31.3431.69 31.50 29.99 Caliper (mils/8 sheets) 152.9 183.1 185.9 204.1 215.2218.7 225.2 236.0 229.9 223.3 MD Tensile (g/3 in) 3,296 2,716 2,7862,651 2,454 2,662 2,624 2,405 2,553 2,363 CD Tensile (g/3 in) 2,6562,479 2,503 2,526 2,420 2,617 2,668 2,478 2,279 2182 GM Tensile (g/3 in)2,958 2,595 2,641 2,588 2,437 2,639 2,646 2,441 2,412 2271 Tensile Ratio1.24 1.10 1.11 1.05 1.01 1.02 0.98 0.97 1.12 1.08 MD Stretch (%) 8.711.0 13.5 17.3 20.3 22.6 25.2 28.5 32.3 32.2 CD Stretch (%) 6.1 7.0 7.78.3 9.0 9.0 9.4 10.1 10.6 10.7 CD Wet Tensile - Finch 797 724 738 747746 788 803 729 728 707 (g/3 in) CD Wet/Dry - Finch (%) 30.0 29.2 29.529.6 30.8 30.1 30.1 29.4 31.9 32.4 Perf Tensile (g/3″) 608 534 577 572562 601 560 495 616 514 SAT Capacity (g/m²) 344 404 385 416 450 465 479530 527 520 SAT Capacity (g/g) 6.7 7.9 7.6 8.2 8.9 9.2 9.4 10.3 10.310.6 SAT Rate (g/sec^(0.5)) 0.09 0.15 0.10 0.12 0.14 0.15 0.15 0.18 0.170.19 GM Break Modulus (g/%) 407.2 295.3 257.7 216.5 180.4 183.4 172.7144.8 130.0 122.8 Roll Diameter (in) 4.57 4.93 5.01 5.03 5.07 5.08 5.155.35 5.12 5.14 Roll Compression (%) 12.1 11.56 12.38 10.06 7.89 7.816.93 8.78 6.90 7.52 Sensory Softness N/C 10.1 9.7 N/C N/C N/C 9.0 9.2N/C N/C

TABLE 12 Trial 11 12 14 15 16 17 18 19 20 21 Fabric 42 42 42 42 42 42 4242 42 42 Fabric Crepe (%) 35 5 8 12 15 17.5 20 25 20 25 Furnish P NP NPNP NP NP NP NP NP NP Basis Weight (lbs/ream) 29.99 31.41 31.67 31.0931.61 31.34 31.60 31.85 31.43 31.26 Caliper (mils/8 sheets) 223.3 175.6183.0 197.8 213.4 212.3 220.6 220.3 200.3 208.2 MD Tensile (g/3 in)2,363 2,878 2,885 2,481 2,447 2,385 2,397 2374 2,684 2424 CD Tensile(g/3 in) 2182 2,495 2,621 2,523 2,563 2,615 2,523 2341 2,545 2591 GMTensile (g/3 in) 2271 2,680 2,750 2,502 2,505 2,497 2,460 2357 2,6132506 Tensile Ratio 1.08 1.15 1.10 0.98 0.95 0.91 0.95 1.01 1.05 0.94 MDStretch (%) 32.2 10.1 12.9 16.9 19.0 20.5 23.0 28.5 23.8 27.4 CD Stretch(%) 10.7 7.2 7.6 8.2 8.1 8.6 8.8 9.6 8.5 8.4 CD Wet Tensile - Finch (g/3in) 707 767 828 825 752 758 752 770 865 738 CD Wet/Dry - Finch (%) 32.430.7 31.6 32.7 29.3 29.0 29.8 32.9 34.0 28.5 Perf Tensile (g/3 in) 514644 668 575 586 496 580 602 614 530 SAT Capacity (g/m²) 520 362 402 430497 490 520 514 473 499 SAT Capacity (g/g) 10.6 7.1 7.8 8.5 9.7 9.6 10.19.9 9.2 9.8 SAT Rate (g/sec^(0.5)) 0.19 0.11 0.14 0.14 0.22 0.23 0.220.20 0.19 0.24 GM Break Modulus (g/%) 122.8 313.3 278.5 211.4 201.2188.2 171.6 144.0 182.3 164.6 Roll Diameter (in) 5.14 4.79 4.84 4.895.13 5.05 5.31 5.10 5.03 5.01 Roll Compression (%) 7.52 8.70 9.02 7.089.48 7.52 11.74 6.86 10.14 7.71 Sensory Softness N/C 9.4 N/C N/C 9.2 N/C9.2 9.1 N/C 8.8

TABLE 13 Trial 22 23 24 25 265 27 28 Fabric 42 45 45 45 45 45 45 FabricCrepe (%) 25 3 5 8 15 20 30 Furnish NP NP NP NP NP NP NP Basis Weight(lbs/ream) 26.22 31.20 31.53 30.83 31.11 31.24 30.98 Caliper (mils/8sheets) 120.3 130.5 137.3 159.3 164.1 172.5 182.3 MD Tensile (g/3 in)2687 2,939 2,742 2,787 2,647 2,649 2,629 CD Tensile (g/3 in) 2518 2,5692,510 2,664 2,726 2,647 2,594 GM Tensile (g/3 in) 2601 2,748 2,623 2,7242,686 2,648 2,611 Tensile Ratio 1.07 1.14 1.09 1.05 0.97 1.00 1.01 MDStretch (%) 30.0 8.4 9.3 18.7 18.1 21.7 31.1 CD Stretch (%) 7.9 5.1 5.06.3 6.4 7.0 7.7 CD Wet Tensile - Finch (g/3 in) 793 732 767 764 756 766789 CD Wet/Dry - Finch (%) 31.5 28.5 30.5 28.7 27.7 28.9 30.4 PerfTensile (g/3 in) 613 621 528 593 637 591 570 SAT Capacity (g/m²) 215 298314 384 386 406 404 SAT Capacity (g/g) 5.0 5.9 6.1 7.7 7.6 8.0 8.0 SATRate (g/sec^(0.5)) 0.04 0.10 0.10 0.14 0.14 0.15 0.14 GM Break Modulus(g/%) 168.2 422.4 385.5 276.5 249.2 213.6 166.6 Roll Diameter (in) 5.244.35 4.36 4.44 4.54 4.61 4.55 Roll Compression (%) 6.16 14.5 13.9 10.09.1 8.4 5.2 Sensory Softness N/C N/C 9.3 N/C N/C 8.7 8.4

Note that Trial 22 only formed a one-ply product, but was otherwiseconverted in the same manner as the other trials.

The results shown in TABLES 11-13 demonstrate the excellent propertiesthat can be achieved using a long warp warn knuckle fabric according toour invention. For example, the final products made with Fabric 42 hadhigher caliper and higher SAT capacity than the comparison products madewith Fabric 45. Further, the results in TABLES 11-13 demonstrate thatvery comparable products can be made with Fabric 42 regardless ofwhether a premium or a non-premium furnish is used.

Based on properties of the products made in the trials described herein,it is clear that the long warp yarn knuckle structuring fabricsdescribed herein can be used in methods that provide products havingoutstanding combinations of properties. For example, the long warp yarnknuckle structuring fabrics described herein can be used in conjunctionwith the non-TAD process described generally above and specifically setforth in the aforementioned '563 patent, (wherein the papermakingfurnish is compactively dewatered before creping) to form an absorbentsheet that has SAT capacities of at least about 9.5 g/g and at leastabout 500 g/m2. Further, this absorbent sheet can be formed in themethod while using a creping ratio of less than about 25%. Even further,the method and long warp yarn knuckle structuring fabrics can be used toproduce an absorbent sheet that has SAT capacities of at least about atleast about 10.0 g/g and at least about 500 g/m2, has a basis weight ofless than about 30 lbs/ream, and a caliper 220 mils/8 sheets. We believethat this type of method has never created such an absorbent sheetbefore.

Although this invention has been described in certain specific exemplaryembodiments, many additional modifications and variations would beapparent to those skilled in the art in light of this disclosure. It is,therefore, to be understood that this invention may be practicedotherwise than as specifically described. Thus, the exemplaryembodiments of the invention should be considered in all respects to beillustrative and not restrictive, and the scope of the invention to bedetermined by any claims supportable by this application and theequivalents thereof, rather than by the foregoing description.

INDUSTRIAL APPLICABILITY

The invention can be used to produce desirable paper products such ashand towels or toilet paper. Thus, the invention is applicable to thepaper products industry.

We claim:
 1. An absorbent cellulosic sheet that has a first side and asecond side, the absorbent sheet comprising: (a) a plurality of domedregions projecting from the first side of the sheet, wherein each domedregion is positioned adjacent to another domed region such that astaggered line of domed regions extends substantially along the machinedirection (MD) of the absorbent sheet; and (b) connecting regionsforming a network interconnecting the domed regions of the absorbentsheet, wherein each connecting region is substantially continuous withtwo other connecting regions such that substantially continuous lines ofconnecting regions extend in a stepped manner along the MD of theabsorbent sheet.
 2. The absorbent sheet according to claim 1, whereineach of the domed regions includes a plurality of indented barsextending across the domed regions in the cross machine direction (CD)of the absorbent sheet.
 3. The absorbent sheet according to claim 2,wherein at least some of the domed regions includes eight indented bars.4. The absorbent sheet according to claim 1, wherein each of the domedregions extends a distance of about 2.5 mm to about 3.0 mm in the MD ofthe absorbent sheet.
 5. The absorbent sheet according to claim 1,wherein the domed regions are rectangular-shaped.
 6. An absorbentcellulosic sheet that has a first side and a second side, the absorbentsheet comprising: (a) a plurality of domed regions projecting from thefirst side of the sheet, wherein each of the domed regions extends (i) adistance of at least 2.5 mm in the machine direction (MD) of theabsorbent sheet, and (ii) includes an indented bar extending across thedomed region in a substantially cross machine direction (CD) of theabsorbent sheet, and wherein the indented bar extends a depth of atleast about 45 microns below adjacent portions of the domed region; and(b) connecting regions forming a network interconnecting the domedregions of the absorbent sheet.
 7. The absorbent sheet according toclaim 6, wherein each of the domed regions includes a plurality ofindented bars.
 8. The absorbent sheet according to claim 6, wherein theindented bars extend a depth of about 90 microns below the adjacentportions of the domed regions.
 9. The absorbent sheet according to claim6, wherein the domed regions extend a distance of about 1.0 mm in the CDof the absorbent sheet.
 10. The absorbent sheet according to claim 6,wherein each of the domed regions extends at least about 2.5 mm to about5.5 mm in the MD of the absorbent sheet.
 11. The absorbent sheetaccording to claim 6, wherein the indented bar extends a depth of about45 microns to about 160 microns below adjacent portions of the domedregion.
 12. An absorbent sheet according to claim 6, wherein each domedregion is positioned adjacent to another domed region such thatstaggered lines of domed regions extend substantially along the MD ofthe absorbent sheet, and wherein each connecting region is substantiallycontinuous with two other connecting regions, such that substantiallycontinuous lines of connecting regions extend in a stepped manner alongthe MD of the absorbent sheet.
 13. The absorbent sheet according toclaim 12, wherein connecting regions extending in the MD of theabsorbent sheet extend a distance of about 0.5 mm in the CD of theabsorbent sheet.
 14. An absorbent cellulosic sheet that has a first sideand a second side, the absorbent sheet comprising: (a) projected regionsextending from the first side of the sheet, the projected regionsextending substantially in the machine direction (MD) of the absorbentsheet, each of the projected regions including a plurality of indentedbars extending across the projected regions in a substantially crossmachine direction (CD) of the absorbent sheet, and the projected regionsbeing substantially parallel to each other; and (b) connecting regionsbetween the projected regions, the connecting regions extendingsubstantially in the MD.
 15. The absorbent sheet according to claim 14,wherein the sheet is a single-ply sheet having a basis weight of lessthan about 27 lbs/ream and a caliper of less than about 180 mils/8sheets.
 16. The absorbent sheet according to claim 14, wherein the sheetis a multi-ply sheet having a basis weight of greater than about 35lbs/ream and a caliper of greater than about 225 mils/8 sheets.